U.S. patent number 9,567,913 [Application Number 13/751,603] was granted by the patent office on 2017-02-14 for systems and methods to extend gas turbine hot gas path parts with supercharged air flow bypass.
This patent grant is currently assigned to General Electric Company. The grantee listed for this patent is General Electric Company. Invention is credited to Dale J. Davis, Sanji Ekanayake, Steven Hartman, Alston Ilford Scipio.
United States Patent |
9,567,913 |
Ekanayake , et al. |
February 14, 2017 |
Systems and methods to extend gas turbine hot gas path parts with
supercharged air flow bypass
Abstract
A system and method for supercharging a combined cycle system
includes a forced draft fan providing a variable air flow. At least
a first portion of the air flow is directed to a compressor and a
second portion of the airflow is diverted to a heat recovery steam
generator. A control system controls the airflows provided to the
compressor and the heat recovery steam generator. The system allows
a combined cycle system to be operated at a desired operating
state, balancing cycle efficiency and component life, by
controlling the flow of air from the forced draft fan to the
compressor and the heat recovery steam generator.
Inventors: |
Ekanayake; Sanji (Mableton,
GA), Scipio; Alston Ilford (Mableton, GA), Hartman;
Steven (Marietta, GA), Davis; Dale J. (Greenville,
SC) |
Applicant: |
Name |
City |
State |
Country |
Type |
General Electric Company |
Schenectady |
NY |
US |
|
|
Assignee: |
General Electric Company
(Schenectady, NY)
|
Family
ID: |
51163649 |
Appl.
No.: |
13/751,603 |
Filed: |
January 28, 2013 |
Prior Publication Data
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Document
Identifier |
Publication Date |
|
US 20140208765 A1 |
Jul 31, 2014 |
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Current U.S.
Class: |
1/1 |
Current CPC
Class: |
F02C
6/18 (20130101); F02C 9/28 (20130101); F02C
6/08 (20130101); F02C 9/18 (20130101); F02C
9/16 (20130101); Y02E 20/14 (20130101); F05D
2270/331 (20130101); F05D 2270/112 (20130101); F05D
2270/3061 (20130101); F05D 2220/70 (20130101); F05D
2270/303 (20130101) |
Current International
Class: |
F02C
9/16 (20060101); F02C 6/18 (20060101); F02C
9/18 (20060101); F02C 6/08 (20060101); F02C
9/28 (20060101) |
Field of
Search: |
;60/39.182,39.5 |
References Cited
[Referenced By]
U.S. Patent Documents
Foreign Patent Documents
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102733870 |
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Oct 2012 |
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CN |
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1245805 |
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Oct 2002 |
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EP |
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2007315213 |
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Dec 2007 |
|
JP |
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4898294 |
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Mar 2012 |
|
JP |
|
Other References
CN office action dated May 27, 2016 that corresponds with CN
Application No. 201410041561.6. cited by applicant .
U.S. Appl. No. 13/485,216, filed May 31, 2012, Conchieri. cited by
applicant .
U.S. Appl. No. 13/485,273, filed May 31, 2012, Ekanayake. cited by
applicant .
U.S. Appl. No. 13/721,870, filed Dec. 20, 2012, Ekanayake. cited by
applicant .
U.S. Appl. No. 13/721,946, filed Dec. 20, 2012, Ekanayake. cited by
applicant .
U.S. Appl. No. 13/485,160, filed May 31, 2012, Ekanayake. cited by
applicant .
Brandon et al, "Inlet Air Supercharging of a 70 kW Microturbine"
Proceedings of GT2006 ASME Turbo Expo 2006: Power for Land, Sea and
Air May 8-11, 2006, Barcelona, Spain. cited by applicant .
Enhanced Turbine Output LLC, 3000 connecticut Ave, suite 317,
Washington DC 20008, "Summary Description of Powercool",
www.etollc.com, May 20, 2004, p. 1-2. cited by applicant .
Howden Brochure, "Variax Axial Flow Fans continually setting new
standards", Howden Denmark NS, Industrivej 23, DK-4700 Naestved,
Denmark, 2009, pp. 1-7, www.howden.com. cited by applicant .
Voith Turbo, Voith Turbo GmbH & Co. KG, Jul. 12, 2002, pp.
1-20, www.Voithturbo.com. cited by applicant .
Wang, T. and Braquet, L, "Assessment of Inlet cooling to enhance
output of a fleet of gas turbines", Proceedings of the Thirtieth
Industrial Energy Technology Conference, IETC 30.sup.1 New Orleans,
May 6-9, 2008. cited by applicant.
|
Primary Examiner: Wongwian; Phutthiwat
Assistant Examiner: Nguyen; Thuyhang
Attorney, Agent or Firm: Cusick; Ernest G. Landgraff; Frank
A.
Claims
What is claimed:
1. A method for extending hot gas path parts life in a turbine
system, the method comprising: determining a desired load;
determining a nominal firing temperature for the desired load;
determining a supercharged firing temperature for the desired load;
determining a first mass flow quantity of air to be provided to a
compressor in the turbine system to achieve the supercharged firing
temperature for the desired load; providing an air flow; and
conveying the first mass flow quantity of air into the compressor,
the method further comprising: determining a desired heat recovery
steam generator inlet temperature; determining a second mass flow
quantity of air to be provided to a heat recovery steam generator
to achieve the desired heat recovery steam generator inlet
temperature; and conveying the second mass flow quantity of air
that bypasses the compressor of the turbine to the heat recovery
steam generator.
2. The method of claim 1, wherein providing an air flow comprises
providing an air flow with a fan.
3. The method of claim 1, wherein conveying the second mass flow
quantity of air to the heat recovery steam generator further
comprises conveying a second mass flow quantity of air at a
predetermined temperature and modulating a heat recovery steam
generator inlet temperature.
4. The method of claim 1, further comprising cooling the first mass
flow quantity of air.
5. The method of claim 1, wherein conveying the second mass flow
quantity of air comprises conveying the second mass flow quantity
of air through a bypass to the heat recovery steam generator.
6. The method of claim 5, further comprising controlling the second
mass flow quantity of air with a valve coupled to the bypass.
7. A method for extending hot gas path parts life in a turbine
system comprising: determining a desired load; determining a
desired maintenance factor; determining an amount of supercharging
required to achieve the desired maintenance factor for the desired
load; determining a first mass flow quantity of air to be provided
to a compressor to achieve the amount of supercharging; determining
a second mass flow quantity of air to be provided to a heat
recovery steam generator; providing an air flow; conveying the
first mass flow quantity of air into the compressor; and conveying
the second mass flow quantity of air that bypasses the compressor
to the heat recovery steam generator.
8. The method of claim 7, wherein providing an air flow comprises
providing an air flow with a fan.
9. The method of claim 7, further comprising: determining a desired
heat recovery steam generator inlet temperature; and wherein
determining a second mass flow quantity of air to be provided to a
heat recovery steam generator comprises determining a second mass
flow quantity of air to be provided to a heat recovery steam
generator to achieve the desired heat recovery steam generator
inlet temperature.
10. The method of claim 9 wherein conveying the second mass flow
quantity of air to the heat recovery steam generator further
comprises conveying a second mass flow quantity of air at a
predetermined temperature and modulating a heat recovery steam
generator inlet temperature.
11. The method of claim 7 wherein conveying the second mass flow
quantity of air comprises conveying the second mass flow quantity
of air through a bypass to the heat recovery steam generator.
12. The method of claim 11 further comprising controlling the
second mass flow quantity of air with a valve coupled to the
bypass.
13. A method for ramping up a combined cycle system having a gas
turbine and a heat recovery steam generator, comprising:
determining a desired load; determining a present load; determining
whether the desired load is greater than the present load;
determining an incremental load increase; determining a desired
firing temperature for the present load plus the incremental load
increase; calculating a first supercharged mass flow to the gas
turbine to achieve the desired firing temperature for the present
load plus the incremental load increase; increasing the present
load to the present load plus the incremental load increase; and
providing the first supercharged mass flow to the gas turbine,
further comprising: determining a desired heat recovery steam
generator inlet temperature for the present load plus the
incremental load increase; calculating a second supercharged mass
flow to a heat recovery steam generator to achieve the desired heat
recovery steam generator inlet temperature for the present load
plus the incremental load increase; and providing the second
supercharged mass flow that bypasses the gas turbine to the heat
recovery steam generator.
14. The method of claim 13, wherein providing the first
supercharged mass flow to the gas turbine comprises providing the
first supercharged mass flow to the gas turbine with a fan.
15. The method of claim 13, wherein providing the second
supercharged mass flow to the heat recovery steam generator
comprises providing the second supercharged mass flow into the heat
recovery steam generator through a bypass.
16. The method of claim 13, wherein providing the second
supercharged mass flow to the heat recovery steam generator
comprises controlling the second supercharged mass flow with a
valve.
17. The method of claim 13, wherein the desired load is a peak
load.
18. The method of claim 14, wherein providing the first
supercharged mass flow to the gas turbine with a fan comprises
driving the fan with a prime mover.
Description
CROSS-REFERENCE TO RELATED APPLICATIONS
This application is related to application Ser. No. 13/485,216,
titled GAS TURBINE COMPRESSOR INLET PRESSURIZATION AND FLOW CONTROL
SYSTEM, filed jointly in the names of John Anthony Conchieri,
Robert Thomas Thatcher, and Andrew Mitchell Rodwell and application
Ser. No. 13/485,273, titled GAS TURBINE COMPRESSOR INLET
PRESSURIZATION HAVING A TORQUE CONVERTER SYSTEM, filed jointly in
the names of Sanji Ekanayake and Alston I. Scipio, each assigned to
General Electric Company, the assignee of the present
invention.
TECHNICAL FIELD
The subject matter disclosed herein relates to combined cycle power
systems and more particularly to supercharged combined cycle
systems with air flow bypass.
BACKGROUND
Combined cycle power systems and cogeneration facilities utilize
gas turbines to generate power. These gas turbines typically
generate high temperature exhaust gases that are conveyed into a
heat recovery steam generator (HRSG) that produces steam. The steam
may be used to drive a steam turbine to generate more power and/or
to provide steam for use in other processes.
Operating power systems at maximum efficiency is a high priority
for any generation facility. Factors including load conditions,
equipment degradation, and ambient conditions may cause the
generation unit to operate under less than optimal conditions.
Supercharging (causing the inlet pressure to exceed the ambient
pressure) turbine systems as a way to increase the capacity of
gas-turbine is known. Supercharged turbine systems typically
include a variable speed supercharging fan located at the gas
turbine inlet that is driven by steam energy derived from
converting exhaust waste heat into steam. The supercharging fan is
used to increase the air mass flow rate into the gas turbine so
that the gas turbine shaft horsepower can be augmented.
Additional high priorities for operators of generation facilities
are maintenance costs and availability. One component of
maintenance costs is equipment life. There are many factors that
influence equipment life, among them are the type of fuel used, the
operating hours at base load, the operating hours at peak load, and
water steam injection into the compressor airflow. These factors
influence the life of hot gas path parts. Increased temperatures in
the turbine may have an impact on the lifetime of the components
positioned along the hot gas path and elsewhere. Typically,
operations above base load will reduce the lifetime of the hot gas
path components while operations below base load generally will
extend component lifetime. Under some conditions an operator may be
willing to sacrifice efficiency for extended life of hot gas path
parts in order to lessen maintenance costs. However, conventional
combined cycle systems do not provide an adequate level of control
of hot gas path parts life.
BRIEF DESCRIPTION OF THE INVENTION
In accordance with one exemplary non-limiting embodiment, the
invention relates to a method for extending life of hot gas path
parts of a turbine system. The method includes the steps of
determining a desired load; determining a nominal firing
temperature for the desired load; and determining a supercharged
firing temperature for the desired load. The method further
includes the steps of determining a first mass flow quantity of air
to be provided to a compressor in the turbine system to achieve the
supercharged firing temperature for the desired load; providing an
air flow; and conveying the first mass flow quantity of air into
the compressor.
In another embodiment, the invention relates to a method for
extending hot gas path parts life in a turbine system. The method
includes the steps of determining a desired load; determining an
efficiency trade off; and determining a desired maintenance factor.
The method further includes the steps of determining an amount of
supercharging required to achieve the desired maintenance factor
for the desired load. The method includes determining a first mass
flow quantity of air to be provided to a compressor to achieve the
amount of supercharging; and determining a second mass flow
quantity of air to be provided to a heat recovery steam generator.
The method further includes the steps of providing an air flow;
conveying the first mass flow quantity of air into the compressor;
and conveying the second mass flow quantity of air to the heat
recovery steam generator.
In another embodiment, the invention relates to a method for
ramping up a combined cycle system having a gas turbine and a heat
recovery steam generator. The method includes the steps of
determining a desired load; determining a present load; and
determining whether the desired load is greater than the present
load. The method further includes the steps of determining an
incremental load increase; and determining a desired firing
temperature for the present load plus the incremental load
increase. The method further includes the steps of calculating a
first supercharged mass flow to the gas turbine to achieve the
desired firing temperature for the present load plus the
incremental load increase; increasing the load to the present load
plus the incremental load increase; and providing the first
supercharged mass flow to the gas turbine.
BRIEF DESCRIPTION OF THE DRAWINGS
Other features and advantages of the present invention will be
apparent from the following more detailed description of the
preferred embodiment, taken in conjunction with the accompanying
drawings which illustrate, by way of example, the principles of
certain aspects of the invention.
FIG. 1 is a schematic illustration of an embodiment of a
supercharged combined cycle system with air bypass.
FIG. 2 is a schematic illustration of another embodiment of a
supercharged combined cycle system with air bypass.
FIG. 3 is a flow chart of an embodiment of a method implemented by
a supercharged combined cycle system with air bypass.
FIG. 4 is a chart illustrating a result accomplished by a
supercharged combined cycle system with air bypass.
FIG. 5 is a flow chart of an embodiment of a method implemented by
a supercharged combined cycle system with air bypass.
FIG. 6 is a chart illustrating a result accomplished by a
supercharged combined cycle system with air bypass.
FIG. 7 is a chart illustrating a result accomplished by a
supercharged combined cycle system with air bypass.
FIG. 8 is a schematic illustration of another embodiment of a
supercharged combined cycle system with air bypass.
FIG. 9 is a schematic illustration of an embodiment of a control
system used to control a supercharged combined cycle system with
air bypass.
FIG. 10 is a schematic illustration of an embodiment of a prime
mover used to drive a forced draft fan.
FIG. 11 is a schematic illustration of an embodiment of a prime
mover used to drive a forced draft fan.
FIG. 12 is a schematic illustration of an embodiment of a prime
mover used to drive a forced draft fan.
FIG. 13 is a schematic illustration of an embodiment of a prime
mover used to drive a forced draft fan.
FIG. 14 is a schematic illustration of an embodiment of a prime
mover used to drive a forced draft fan.
FIG. 15 is a schematic illustration of an embodiment of a prime
mover used to drive a forced draft fan.
FIG. 16 is a table summarizing the advantages and disadvantages of
different prime movers.
FIG. 17 is a chart showing the relationship between output and a
change in T-fire for a gas turbine that is not supercharged
(nominal) and a gas turbine that is supercharged by 10%.
FIG. 18 is a chart illustrating the impact of supercharging on the
maintenance factor.
FIG. 19 is a chart illustrating the impact of supercharging on
T-fire, heat rate and output at peak load.
FIG. 20 is a chart illustrating the impact of supercharging on
T-fire, heat rate and output at base load.
FIG. 21 is a chart illustrating the impact of supercharging on
T-fire, heat rate and output at 90% load.
FIG. 22 is a chart illustrating the impact of supercharging on
T-fire, heat rate and output at 80% load.
FIG. 23 is a flow chart for a method for extending the life of hot
gas path parts of a gas turbine system using supercharging.
FIG. 24 is a flowchart of a method for reducing a maintenance
factor in a turbine system.
FIG. 25 is a flow chart of a method for operating a combined cycle
system having a gas turbine and an HRSG.
FIG. 26 is a flow chart for a method for ramping up a combined
cycle system having a gas turbine and an HRSG.
DETAILED DESCRIPTION OF THE INVENTION
FIG. 1 is a schematic illustration of a supercharged combined cycle
system with air bypass (SCCAB system 11) in accordance with one
embodiment of the present invention. The SCCAB system 11 includes a
gas turbine subsystem 13 that in turn includes a compressor 15,
having a compressor inlet 16, a combustor 17 and a turbine 19. An
exhaust duct 21 may be coupled to the turbine 19 and a heat
recovery steam generator subsystem (HRSG 23). The HRSG 23 recovers
heat from exhaust gases from the turbine 19 that are conveyed
through HRSG inlet 24 to generate steam. The HRSG 23 may also
include a secondary burner 25 to provide additional energy to the
HRSG 23. Some of the steam and exhaust from the HRSG 23 may be
vented to stack 27 or used to drive a steam turbine 26 and provide
additional power. Some of the steam from the HRSG 23 may be
transported through process steam outlet header 28 to be used for
other processes. The SCCAB system 11 may also include an inlet
house and cooling system 29. The inlet house and cooling system 29
is used to cool and filter the air entering the compressor inlet 16
to increase power and avoid damage to the compressor 15.
The SCCAB system 11 also includes a forced draft fan 30 used to
create a positive pressure forcing air into the compressor 15.
Forced draft fan 30 may have a fixed or variable blade fan (not
shown). Forced draft fan 30 may be driven by a prime mover 31. The
forced draft fan 30 provides a controllable air stream source
though a duct assembly 32 and may be used to increase the mass flow
rate of air into the compressor 15. The quantity of air going into
the compressor is controlled by the prime mover 31. The compressor
inlet 16 may be configured to accommodate slight positive pressure
as compared to the slight negative pressure of a conventional
design.
The SCCAB system 11 may also include a bypass 33 (which may include
external ducting) that diverts a portion of the air flow from
forced draft fan 30 into the exhaust duct 21. This increased air
flow provides additional oxygen to the secondary burner 25 to avoid
flame out or less than optimal combustion. Bypass 33 may be
provided with a flow sensor 35 and a damper valve 37 to control the
airflow through the bypass 33. A control system 39 may be provided
to receive data from flow sensor 35 and to control the damper valve
37 and the prime mover 31. Control system 39 may be integrated into
the larger control system used for operation control of SCCAB
system 11. The airflow from the bypass is conveyed to the exhaust
duct 21 where the temperature of the combined air and exhaust
entering the HRSG 23 may be modulated.
Illustrated in FIG. 2 is another embodiment of a SCCAB system 11
that includes a pair of gas turbine subsystem(s) 13. In this
embodiment, the exhaust of the pair of gas turbine subsystem(s) 13
is used to drive a steam turbine 26. In this embodiment, an inlet
house 41 is positioned upstream of the forced draft fan 30, and a
cooling system 43, where the airflow from the fan may be cooled, is
positioned downstream of the forced draft fan 30. The bypass 33 is
coupled to the cooling system 43. One of ordinary skill in the art
will recognize that although in this embodiment two gas turbine
subsystem(s) 13 are described, any number of gas turbine
subsystem(s) 13 in combination with any number of steam turbine(s)
26 may be used.
In operation, the SCCAB system 11 provides increased air flow into
the HRSG 23 resulting in a number of benefits. The SCCAB system 11
may provide an operator with the ability to optimize combined cycle
plant flexibility, efficiency and lifecycle economics. For example,
boosting the inlet pressure of the gas turbine subsystem 13
improves output and heat rate performance. The output performance
of the SCCAB system 11 may be maintained flat (zero degradation)
throughout the life cycle of SCCAB system 11 by increasing the
level of supercharging (and parasitic load to drive the forced
draft fan 30) over time commensurate with the degradation of SCCAB
system 11. Another benefit that may be derived from the SCCAB
system 11 is the expansion of the power generation to steam
production ratio envelope. This may be accomplished by modulating
the exhaust gas temperature at HRSG inlet 24 with air from the
forced draft fan 30. Another benefit that may be derived from the
SCCAB system 11 is an improved start up rate as a result of the
reduction in the purge cycle (removal of built up gas). The SCCAB
system 11 may also provide an improved load ramp rate resulting
from the modulation of the exhaust temperature at the exhaust duct
21 with air from the forced draft fan 30 provided through the
bypass 33. The forced draft fan 30 of the SCCAB system 11 also
provides an effective means to force-cool the gas turbine subsystem
13 and HRSG 23, reducing maintenance outage time and improving
system availability. The forced draft fan 30 provides comparable
benefit for simple cycle and combined-cycle configurations for all
gas turbine subsystem(s) 13 delivering in the range of 20% output
improvement under hot ambient conditions with modest capital
cost.
The SCCAB system 11 may implement a method of maintaining the
output of a combined cycle plant over time (method 50) as
illustrated with reference to FIG. 3. In step 51, the method 50 may
determine the current state, and in step 53, the method 50 may
determine a desired state. The desired state may be to maintain a
nominal output over time to compensate for performance losses.
Performance losses typically arise as a result of wear of
components in the gas turbine over time. These losses may be
measured or calculated. In step 55, the method 50 may determine the
required increased air mass flow to maintain the desired output.
Based on that determination, the method 50 may, in step 57 adjust
the air mass flow into the compressor inlet 16. In step 59, the
method 50 may adjust the combined air and exhaust mass flow into
the HRSG inlet 24.
FIG. 4 illustrates the loss of output and heat rate over time
(expressed in percentages) of a conventional combined cycle system
and a SCCAB system 11. Gas turbines suffer a loss in output over
time, as a result of wear of components in the gas turbine. This
loss is due in part to increased turbine and compressor clearances
and changes in surface finish and airfoil contour. Typically
maintenance or compressor cleaning cannot recover this loss, rather
the solution is the replacement of affected parts at recommended
inspection intervals. However, by increasing the level of
supercharging using forced draft fan 30, output performance may be
maintained, although at a cost due to the parasitic load to drive
the forced draft fan 30. The top curve (unbroken double line)
illustrates the typical output loss of a conventional combined
cycle system. The second curve (broken double lines) illustrates
the expected output loss with periodic inspections and routine
maintenance. The lower curve (broken triple line) shows that the
output loss of an SCCAB system 11 may be maintained at near 0%.
Similarly, the heat rate degradation of a conventional combined
cycle system (single solid curve) may be significantly improved
with an SCCAB system 11.
FIG. 5 illustrates a method of controlling the steam output of a
SCCAB system 11 (method 60). In step 61, method 60 may initially
determine the current state. In step 63, the method 60 may also
determine the desired output and steam flow. In step 65, the method
60 may determine the required increased air flow to the compressor
inlet 16 and the HRSG inlet 24. In step 67, method 60 may then
adjust the air flow into the compressor inlet 16 and in step 69,
adjust the combined exhaust and air flow into the HRSG inlet 24, to
provide the desired steam output.
FIG. 6 illustrates an expanded operating envelope available to
maintain constant steam flow. The vertical axis measures output in
MW and horizontal axes measures steam mass flow. The interior area
(light vertical cross hatch) shows the envelope of a conventional
combined cycle system. The envelope of an SCCAB system 11 is shown
in diagonal cross hatching, and a larger area illustrates the
performance of an SCCAB system 11 combined with secondary firing in
the HRSG 23.
FIG. 7 is a chart that illustrates the improved operational
performance of an SCCAB system 11 at a specific ambient temperature
in comparison with conventional combined cycle systems at minimum
and base loads. The horizontal axis measures output in MW and the
vertical axis measures heat rate (the thermal energy (BTU's) from
fuel required to produce one kWh of electricity). The chart
illustrates the improved efficiency delivered by the SCCAB system
11.
Illustrated in FIG. 8 is a schematic illustration of a combined
cycle system 111 in accordance with another embodiment of the
present invention. The combined cycle system 111 includes a gas
turbine subsystem 113 that in turn includes a compressor 115,
having a compressor inlet 116, a combustor 117 and a turbine 119.
An exhaust duct 121 may be coupled to the gas turbine subsystem 113
and a heat recovery steam generator subsystem (HRSG 123). The HRSG
123 recovers heat from exhaust gases from the gas turbine subsystem
113 that are conveyed through HRSG inlet 124 to generate steam.
Some of the steam and exhaust from the HRSG 123 may be used to
drive a steam turbine 126 and provide additional power, or vented
to stack 127. Some of the steam from the HRSG 123 may be
transported through process steam outlet header 128 to be used for
other processes.
The combined cycle system 111 also includes a forced draft fan 130
used to create a positive pressure forcing air into the compressor
115. Forced draft fan 130 may be a fixed or variable blade fan.
Forced draft fan 130 may be driven by a prime mover 131. The forced
draft fan 130 provides a controllable air stream source though a
duct assembly 132 and may be used to increase the mass flow rate of
air into the gas turbine subsystem 113. The quantity of air going
into the gas turbine subsystem 113 is controlled by the prime mover
131.
The combined cycle system 111 may also include an inlet house 141
and cooling system 143. The inlet house 141 and cooling system 143
cool and filter the air entering the gas turbine subsystem 113 to
increase power and avoid damage to the compressor. In some
embodiments the inlet house 141 and the cooling system 143 may be
combined and disposed downstream from the forced draft fan 130.
The combined cycle system 111 may also include a bypass 133 (which
may include external ducting) that diverts a portion of the air
flow from forced draft fan 130 into the exhaust duct 121. Bypass
133 may be provided with a flow sensor 139 and a bypass damper
valve 137 to control the airflow through the bypass 133. The
airflow from the bypass is conveyed to the exhaust duct 121 where
the temperature of the combined air and exhaust entering the HRSG
123 may be modulated.
The combined cycle system 111 may also include a drive bypass 145
coupled to the prime mover 131. The drive bypass 145 is provided
with a drive damper valve 146 and a drive system sensor 147. The
prime mover 131 may also be provided with a secondary conduit 148
having a secondary damper valve 149 and a secondary sensor 150. The
prime mover is coupled to the forced draft fan 130 by a conduit
151. In some embodiments, the exhaust of the prime mover 131 may be
conveyed to the HRSG 123 through a drive exhaust conduit 155.
In operation, the prime mover 131 drives the forced draft fan 130
to provide an air flow at a predetermined mass flow rate. The air
flow may be cooled by cooling system 143. The airflow may be
divided into a first mass flow quantity to be conveyed to the
compressor inlet 116, a second mass flow quantity to be conveyed to
the exhaust duct 121, and in some cases a third mass flow quantity
to be conveyed to the prime mover 131. Control of the first mass
flow quantity, the second mass flow quantity, and the third mass
flow quantity is effected through the controls of bypass damper
valve 137, drive damper valve 146, and secondary damper valve 149.
By controlling the first mass flow quantity, the second mass flow
quantity and the third mass flow quantity the operator is provided
with more effective control of the operating envelope of the
combined cycle system 111.
FIG. 9 illustrates the control system 161 used to control bypass
damper valve 137, drive damper valve 146 and secondary damper valve
149. Control system 161 receives readings from flow sensor 139,
drive system sensor 147 and secondary sensor 150. The control
system 161 may be a conventional General Electric Speedtronic.TM.
Mark VI Gas Turbine Control System. The SpeedTronic controller
monitors various sensors and other instruments associated with a
gas turbine. In addition to controlling certain turbine functions,
such as fuel flow rate, the SpeedTronic controller generates data
from its turbine sensors and presents that data for display to the
turbine operator. The data may be displayed using software that
generates data charts and other data presentations, such as the
General Electric Cimplicity.TM. HMI software product.
The Speedtronic.TM. Mark VI Gas Turbine Control System is a
computer system that includes microprocessors that execute programs
to control the operation of the gas turbine using sensor inputs and
instructions from human operators. The control system includes
logic units, such as sample and hold, summation and difference
units, which may be implemented in software or by hardwire logic
circuits. The commands generated by the control system processors
cause actuators on the gas turbine to, for example, adjust the fuel
control system that supplies fuel to the combustion chamber, set
the inlet guide vanes to the compressor, and adjust other control
settings on the gas turbine.
Illustrated in FIG. 10 is an embodiment where the prime mover 131
is a gas turbine 159. Gas turbine 159 provides certain benefits
over another type of prime mover 131. These benefit include greater
reliability, particularly in applications where sustained high
power output is required and high efficiencies at high loads. The
drawbacks to the use of a gas turbine 159 as a prime mover 131
include lower efficiency than reciprocating engines at part loads
and higher costs. In operation the gas turbine 159 receives
supercharged and cooled air through drive bypass 145 and its
exhaust may be conveyed to the HRSG 123 though drive exhaust
conduit 155 for best cycle efficiency and flexibility. This results
in excellent full-load and part-load efficiency and operational
flexibility. The forced draft fan 130 driven by gas turbine 159
eliminates output degradation over time by trading efficiency to
make up for output degradation. The forced draft fan 130 driven by
gas turbine 159 also provides the operator with the ability to
expand the power generation to steam production ratio envelope.
Furthermore, the forced draft fan 130 driven by gas turbine 159,
increases net power production and improves efficiency of gas
turbine subsystem 113 and combined cycle system 111. By expanding
the operating envelope, the operator may reduce the negative
capital & operating cost impact of needing to add a unit at a
multi-unit power block where there is a partial output shortfall.
The use of a gas turbine 159 has the disadvantages of high capital
and maintenance costs. Gas turbine 159 provides a subsystem of
medium complexity with high cycle efficiency and very high peak
output at fixed supercharger boost.
FIG. 11 illustrates another embodiment where an aeroderivative gas
turbine 171 is used as the prime mover 131. An aeroderivative gas
turbine 171 is a gas turbine derived from an aviation turbine. The
decision to use aeroderivative gas turbine 171 is mainly based on
economical and operational advantages. They are relatively light
weight and offer high performance and efficiency. Aeroderivative
gas turbine 171 permits efficient control of torque together with
potential for integrated control. Common economic/operational
advantages and benefits of the aeroderivative gas turbine 171
compared to conventional heavy frame gas turbine drivers are a 10
to 15 percent improvement in efficiency. An aeroderivative gas
turbine 171 provides a smooth, controlled start. Aeroderivative gas
turbine 171 has higher availability and operational reliability and
its wide load range permits economically optimized power control.
An aeroderivative gas turbine 171 also provides an advantage over
conventional heavy frame gas turbine drivers due to its ability to
be shut down, and ramped up rapidly and to handle load changes more
efficiently. An aeroderivative gas turbine 171 provides high cycle
efficiency and very high peak output at a fixed supercharger boost.
The advantages of the aeroderivative gas turbine 171 for this
application must be balanced against some disadvantages, including
high capital costs and very high maintenance costs.
FIG. 12 illustrates another embodiment where a steam turbine 173 is
used as the prime mover 131. A steam turbine is a device that
extracts thermal energy from pressurized steam and uses it to do
mechanical work on a rotating output shaft. The use of a steam
turbine 173 provides the advantage of being able to use wide range
of fuels to drive the steam turbine 173. In comparison to the other
prime movers, the steam turbine has an average capital cost,
maintenance cost, cycle efficiency, and peak output at fixed
supercharger boost. Steam turbine 173 also has a high subsystem
complexity. However, steam turbine 173 has the disadvantage of
requiring boiler and other equipment and a higher
price-to-performance ratio. A steam turbine 173 has a slow load
change behavior, which means once running the steam turbine 173
cannot be stopped quickly. A specific amount of time is needed to
slow down its revolutions. A steam turbine 173 also has poor part
load performance.
FIG. 13 illustrates another embodiment where an induction motor 175
is used as the prime mover 131. An induction motor 175 is a type of
AC motor where power is supplied to the rotor by means of
electromagnetic induction, rather than a commutator or slip rings
as in other types of motors. Induction motor 175 has the advantage
of being rugged, easy to operate, and having low capital and
maintenance costs. Induction motor 175 also has the advantage of
providing a subsystem of low complexity. Another advantage of an
induction motor 175 is the ability to regulate the torque output
and modulate the energy output of the induction motor 175.
Induction motor 175 has the disadvantage of low cycle efficiency
and low peak output at fixed supercharger boost.
FIG. 14 illustrates another embodiment where a reciprocating engine
177 is used as the prime mover 131. The reciprocating engine 177,
also often known as a piston engine, is a heat engine such as a
diesel engine that uses one or more reciprocating pistons to
convert pressure into a rotating motion. Use of a reciprocating
engine 177 to drive the forced draft fan 130 has the advantage of
providing high efficiencies at part load operation and high cycle
efficiencies. Peak output at fixed supercharger boost is very high
with a reciprocating engine 177. Additionally a reciprocating
engine 177 has short start-up times to full loads. A reciprocating
engine has average capital costs and maintenance cost. The
complexity of the subsystem is average when compared to other prime
movers.
Illustrated in FIG. 15 is another embodiment where a variable
frequency drive (VFD 179) is used as the prime mover 131. VFD 179
is a drive that controls the rotational speed of an electric motor
by controlling the frequency of the electrical power supplied to
the motor. VFD 179 provides a number of advantages, including low
subsystem complexity and low maintenance costs as well as energy
savings from operating at lower than nominal speeds. VFD 179 has
average capital costs when compared with other prime movers and
provides average cycle efficiency. Another advantage is that VFD
179 may be gradually ramped up to speed, lessening the stress on
the equipment. A disadvantage is lower than average peak output at
a fixed supercharger boost.
The advantages and disadvantages of the different prime mover(s)
131 are summarized in the table in FIG. 16.
Illustrated in FIG. 17 is the relationship between output and a
change in the firing temperature ("T-fire") for a gas turbine that
is not supercharged (nominal) and a gas turbine that is
supercharged by 10%. From the chart it is apparent that for a given
output, a lower T-fire can be obtained with supercharging. The
difference is most pronounced at peak loads where under nominal
operations the change in T-fire is positive (i.e. T-fire increases
when compared to T-fire at base load.). But, under supercharged
conditions the change in T-fire remains negative.
Illustrated in FIG. 18 is the impact of supercharging on the
maintenance factor. Again, at peak loads the maintenance factor is
significantly lower in the supercharged case compared to the
maintenance factor for the nominal case.
FIG. 19 illustrates the impact of supercharging on T-fire, heat
rate and output at peak load. From the delta T-fire curve, it can
be ascertained that significant negative change in T-fire may be
obtained by supercharging without any impact on output. FIGS. 20-22
illustrate the impact of supercharging on T-fire, heat rate and
output at base load, 90% load, and 80% load respectively. The
charts illustrate the impact of supercharging on delta T-fire, in
effect demonstrating that supercharging can reduce T-fire at
different loads without having a significant impact on the
output.
Illustrated in FIG. 23 is a flowchart for a method 200 for
extending the life of hot gas path parts of a gas turbine system
using supercharging.
In step 210, the method 200 determines a desired load.
In step 220, the method 200 determines a nominal T-fire for the
desired load.
In step 230, the method 200 determines the available reduction in
T-fire with supercharging for the desired load.
In step 240, the method 200 determines a desired reduction in
T-fire.
In step 250, method 200 calculates the supercharged mass flow
required to achieve the reduction in T-fire.
In step 260, the method 200 increases the load to the desired
load.
In step 270, the method 200 provides the supercharged mass flow
required to achieve the reduction in T-fire.
If the gas turbine system includes an HRSG, the method 200 may
implement a step 280 to determine a nominal HRSG inlet
temperature.
In step 290, the method 200 may determine the available HRSG inlet
temperature reduction with supercharging.
In step 300 the method 200 may determine the desired steam turbine
inlet temperature reduction to achieve a desired HRSG inlet
temperature. The method 200 proceeds to step 242 to determine the
desired T-fire reduction. By reducing T-fire and the HRSG inlet
temperature an operator can decrease the maintenance factor hot gas
path components of the gas turbine and hot gas path components of
the steam turbine coupled to the HRSG.
Illustrated in FIG. 24 is a flowchart of a method 400 for reducing
a maintenance factor in a turbine system.
In step 410, the method 400 determines a desired load.
In step 420, the method 400 determines a nominal maintenance factor
for the desired load.
In step 430, the method 400 determines the available maintenance
factor decrease for the desired load with supercharging.
In step 440, the method 400 determines the desired maintenance
factor.
In step 450, the method 400 calculates the supercharged mass flow
required to achieve the desired maintenance factor.
In step 460, the method 400 ramps up the supercharge to the desired
boost pressure and mass flow.
In step 470, the method 400 provides the supercharge mass flow to
achieve the desired maintenance factor to the combustor
exhaust.
In step 480 the gas turbine system is adjusted to the desired load
and maintenance factor.
Illustrated in FIG. 25 is a flow chart of a method 500 for
operating a combined cycle system having a gas turbine and an
HRSG.
In step 510, the method 500 determines a desired output.
In step 520, the method 500 determines the nominal T-fire for the
desired output.
In step 530, the method 500 determines the nominal HRSG inlet
temperature for the desired output.
In step 540, the method 500 determines the T-fire reduction
available with supercharging.
In step 550, the method 500 determines the available steam turbine
inlet temperature with supercharging.
In step 560, the method 500 determines the desired T-fire.
In step 570, the method 500 determines the desired HRSG inlet
temperature.
In step 580, the method 500 calculates the supercharged mass flow
required to achieve the reduction in T-fire.
In step 590, the method 500 calculates the supercharged mass flow
(second supercharged mass flow provided at a predetermined
temperature) that is required to achieve the desired HRSG inlet
temperature.
In step 600, the method 500 increases the amount of supercharging
to increase the boost pressure and mass flow to the required
level.
In step 610, the method 500 provides the desired load, the desired
gas turbine maintenance factor and the HRSG inlet temperature.
Illustrated in FIG. 26 is a flow chart for a method 700 for ramping
up a combined cycle system having a gas turbine and an HRSG.
In step 710, the method 700 determines the desired load.
In step 720, the method 700 determines the present load.
In step 730, the method 700 determines whether the present load is
equal to the desired load. If the present load is equal to desired
load the method ends (step 740). If the present load is not equal
to the desired load, then the method proceeds to step 750.
In step 750, the method 700 determines an incremental change in
load.
In step 760, the method 700 determines a desired T-fire. The
desired T-fire may be determined by determining the nominal T-fire
of the gas turbine the present load plus the incremental change in
the load (step 770).
In step 780, the method 700 may determine the T-fire reduction
available with supercharging.
In step 790, the method 700 may calculate the mass flow to be
provided by the supercharger to the gas turbine in order to achieve
the desired T-fire.
In step 800, the method 700 ramps up the load by the incremental
load.
If the system has an HRSG, then the method 700 may determine in
step 810 a desired HRSG inlet temperature.
In step 820, the method 700 may calculate the mass flow to be
provided by the supercharger to the HRSG to achieve the desired
HRSG inlet temperature.
In step 830, the method 700 may provide the HRSG supercharge mass
flow (secondary supercharged mass flow, controlled through bypass
damper valve 137) to the HRSG.
In step 840, the method 700 may provide the supercharged mass flow
to the gas turbine, and repeat step 720 to determine the present
load and step 730 to determine if the present load is equal to the
desired load.
The foregoing detailed description has set forth various
embodiments of the systems and/or methods via the use of block
diagrams, flowcharts, and/or examples. Insofar as such block
diagrams, flowcharts, and/or examples contain one or more functions
and/or operations, it will be understood by those within the art
that each function and/or operation within such block diagrams,
flowcharts, or examples can be implemented, individually and/or
collectively, by a wide range of hardware. It will further be
understood that method steps may be presented in a particular order
in flowcharts, and/or examples herein, but are not necessarily
limited to being performed in the presented order. For example,
steps may be performed simultaneously, or in a different order than
presented herein, and such variations will be apparent to one of
skill in the art in light of this disclosure.
This written description uses examples to disclose the invention,
including the best mode, and also to enable any person skilled in
the art to practice the invention, including making and using any
devices or systems and performing any incorporated methods. The
patentable scope of the invention is defined by the claims, and may
include other examples that occur to those skilled in the art. Such
other examples are intended to be within the scope of the claims if
they have structural elements that do not differ from the literal
language of the claims, or if they include equivalent structural
elements with insubstantial differences from the literal languages
of the claims.
* * * * *
References